Patent Application
20240269623
Energy production from processes such as power plants, which burn natural gas, coal, or other hydrocarbon-based fuels, or methane generation from biological degradation of waste organic materials, such as manure, produce gaseous effluents comprising carbon dioxide (CO2). In power plants, the effluent (flue gas) contains CO2 at approximately 12-15% v/v, nitrogen (N2), and water vapor from the combustion of air. Mixtures of CO2 and methane from biological degradation also contain hydrogen sulfide, and water vapor. It can be desirable to recover methane for its energy content while CO2 is known to contribute to global warming. Therefore, it can also be desirable, especially in power generation, to recover the CO2 and reduce emissions to the environment. Carbon dioxide capture and sequestration (CCS) has been proposed for separation and subsequent injection of CO2 into underground storage sites. The overall CCS process needs to be highly efficient to minimize costs associated with compression since CO2-containing effluents are usually at low concentrations (˜10 to 40%) and low partial pressures (˜5 to 30 psia) and may be close to atmospheric pressure, making separation economically challenging. Processes for CCS have included amine scrubbing, wherein CO2 reversibly reacts with a liquid amine to form an ammonium-CO2 complex, and membrane separation.
Enhanced membrane CO2 separation through a facilitated transport mechanism using a membrane incorporating amine functionality was known. For example. Deng et al. in U.S. Pat. No. 7,896,948 disclosed a method for separating carbon dioxide from a gas mixture using a thin-film membrane having a gas-separation layer incorporating a blend of polyvinyl alcohol and polyvinylamine. Ho et al. in U.S. Pat. No. 10,835,847 disclosed a method of separating a gaseous mixture comprising carbon dioxide using a membrane incorporating a selective polymer layer comprising an amine-containing polymer, such as polyvinylamine, and an amino acid salt dispersed within the amine-containing polymer. Polyvinylamine is a stable glassy polymer when dry and has glass transition temperature between 120 and 130° C. However, these membrane materials are water-soluble and without a stabilization strategy, they can be highly plasticized due to swelling such that they might be easily damaged from process upsets because of the significant water vapor pressure that is required for CO2 separation performance.
This invention discloses a fluorinated copolymer having nitrogen functionality in the form of pendant amide functionality, a membrane incorporating certain amine derivatized compositions of the fluorinated copolymer, and processes using the membrane for the separation of carbon dioxide from gas mixtures with nitrogen or methane. The fluorinated copolymer comprises a first repeating unit, a second repeating unit, and has a backbone comprising a fluorinated and cyclic structure from the first repeating unit. The second repeating unit comprises a pendant amide functionality and has the following structure:
wherein X is H or an alkyl group, R1 is H, an alkyl group, or an alkyl group that together with X form a cyclic ring with the proviso that X is not H.
In an aspect disclosed herein, free-radical copolymerization of a fluoromonomer that is cyclic, such as 4,5-Difluoro-2,2-bis(trifluoromethyl)-1,3-dioxole (PDD), or is otherwise cyclizable during free-radical copolymerization, is used to form the first repeating unit having a fluorinated and cyclic structure within the backbone of the fluorinated copolymer. Copolymerization with a vinyl amide comonomer, such as N-vinyl formamide or N-methyl-N-vinyl acetamide, results in the second repeating unit having a pendant amide functionality. Derivatization of the nitrogen functionality in the fluorinated copolymer through a hydrolysis reaction can be used to transform pendant amide functionality to pendant amine functionality and form an amine derivatized fluorinated copolymer. In another aspect disclosed herein, the amine derivatized fluorinated copolymer having a fraction, preferably greater than 50% of the pendant amide functionality transformed to pendant amine functionality, is useful for a membrane, and is particularly useful as a gas-separation layer in a thin-film composite membrane. In yet another aspect disclosed herein, the membrane is useful for separation of carbon dioxide (CO2) from nitrogen or methane.
The fluorinated copolymer having a fluorinated and cyclic structure within the backbone from the first repeating unit can have a high glass transition temperature above 130° C. The fluorinated and cyclic structure helps to reduce water solubility and may also help to increase CO2 permeability for the fluorinated copolymer in a membrane or gas-separation layer in a thin-film composite membrane. The amine functionality in the amine derivatized fluorinated copolymer may help to increase CO2 selectivity over gases such as nitrogen (N2) or methane (CH4) through a facilitated transport mechanism. A thin-film composite membrane, having a thickness for the gas-separation layer that is between 0.1 and 0.5-μm, may have a CO2 to nitrogen or methane selectivity of at least 20. The corresponding CO2 permeance may be at least 500×(10−6×cm3 (STP)/cm2/sec/cmHg) (500 gas permeation units or 500-GPU), and preferably at least 1000-GPU at ambient (20 to 25° C.) temperatures. This separation performance may be realized at operating conditions that include feed pressures that are 90-psig or lower, and/or CO2 partial pressures that are 40% or less of total feed pressure.
This summary of the invention introduced some of the embodiments of the invention and is not intended to be limiting. Additional embodiments including variations and alternative configurations of the invention are further described in the detailed description of the invention and the examples. Certain exemplary embodiments of the present invention are described herein and are illustrated in the accompanying FIGURE. The embodiments described are only for purposes of illustrating the present invention and should not be interpreted as limiting the scope of the invention. Other embodiments of the invention, and certain modifications, combinations, and improvements of the described embodiments will occur to those skilled in the art and all such alternate embodiments, combinations, modifications, improvements are within the scope of the present invention.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. In addition, use of “a” or “an” are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise. Certain additional terms are also used and some of them are further defined within the following detailed description of the invention.
The accompanying
A membrane for industrial CO2/N2 (or CO2/methane) separation should be highly permeable to CO2 and preferably possess a selectivity over nitrogen (or methane) of at least 20, more preferably greater than 30. Polymer materials for a necessarily thin gas-separation layer in a thin-film composite membrane should be mechanically and thermally stable, and easy to fabricate into large-area composite membrane modules. The gas-separation layer should have a long working lifetime with resistance to degradation from the effects of water vapor or adventitious contact with liquid water. Gas-separation layers from certain polymer materials that incorporate a fluorinated and cyclic repeating unit structure within the polymer backbone can have high permeance, reduced water solubility, and high glass-transition temperatures. Gas-separation layers from polymer materials that also incorporate amine functionality may have increased CO2 to N2 (or CO2 to methane) selectivity through a facilitated transport mechanism and are desirable for industrial-scale separations.
In an aspect of the invention, a fluorinated copolymer is prepared by copolymerization of a fluoromonomer to form a first repeating unit and a vinyl amide comonomer to form a second repeating unit. The fluoromonomer that forms the first repeating unit may be cyclic or is otherwise cyclizable from free-radical copolymerization and becomes the first repeating unit that is fluorinated and cyclic within the copolymer backbone structure. Fluoromonomers that are cyclic include 4,5-Difluoro-2,2-bis(trifluoromethyl)-1,3-dioxole (PDD), 2,2,4-trifluoro-5-trifluoromethoxy-1,3-dioxole (TFMD), perfluoro(2-methylene-4-methyl-1,3-dioxolane) (PFMMD), and perfluoro(2-methylene-1,3-dioxolane) (PFMD). Fluoromonomers that are cyclizable from free radical copolymerization include perfluoro(4-vinyloxyl-1-butene) (PVOB). PDD is relatively more reactive to free-radical copolymerization, commercially available, and is a preferred fluoromonomer. Vinyl amide comonomers to form the second repeating unit include N-vinyl formamide, N-vinyl acetamide, N-methyl-N-vinyl acetamide, 1-vinyl-2-pyrrolidinone, or N-vinyl caprolactam may be used to form a second repeating unit. N-vinyl formamide and N-methyl-N-vinyl acetamide are liquids at ambient room temperature, readily commercially available, have relatively simple structures, and are therefore preferred.
The fluorinated copolymers are synthesized by free-radical copolymerization using known polymerization techniques, which can include emulsion copolymerization, solution copolymerization, and precipitation copolymerization. In a precipitation copolymerization, a solvent for the fluorinated monomer, vinyl amide comonomer, and initiator may not be solvent for the fluorinated copolymer that is formed in the copolymerization reaction mixture. Solution or precipitation copolymerization with use of a solvent is preferred for a small-scale (<1-L volume) copolymerization process. The free-radical copolymerization may be conducted in batch, semi-batch, or continuous copolymerization processes. A preferred solvent for the copolymerization should not significantly contribute to chain transfer reactions during copolymerization. Preferred solvents or solvent mixtures have included mixtures of methyl acetate and tert-butanol.
The free-radical copolymerization is conducted in the absence of oxygen in a copolymerization vessel that is configured for the containment and mixing of a copolymerization reaction mixture. The copolymerization vessel is preferably a pressure vessel to minimize loss of volatile or gaseous components and is constructed of any suitable material, preferably glass or metal. The copolymerization vessel is preferably configured with ports, valves, or pumps for the addition of the fluoromonomer, vinyl amide monomer, solvent, and free-radical initiator. The copolymerization vessel may also be configured with additional equipment such as for heating, or a chiller for cooling and removal of copolymerization reaction heat and maintaining a constant reaction temperature in the copolymerization reaction mixture. The copolymerization reaction temperature is generally in the range of 0° C. to 80° C. more preferably in the range of 50° C. to 70° C. Azo-like initiators are preferred initiators for the free-radical copolymerization. 2,2′-Azobisisobutyronitrile (AIBN) is especially preferred. The free-radical initiator may be pre-dissolved with all or a part of the solvent to form an initiator solution and is added at the beginning of the copolymerization. Additional initiator solution may be added to the copolymerization reaction mixture throughout the copolymerization reaction time to maintain a consistent initiator concentration. A practical copolymerization reaction time for a batch copolymerization is at least 1 hour, preferably between 1 to 24 hours, and more preferably between 8 and 16 hours when using a preferred PDD fluoromonomer and N-vinyl formamide as the vinyl amide monomer.
The copolymerization reaction mixture is subsequently removed from the copolymerization vessel and separated to isolate the fluorinated copolymer, and optionally recover the remaining fluoromonomer, remaining vinyl amide monomer, and solvent. The fluorinated copolymer may be isolated from the copolymerization reaction mixture using techniques that include precipitation, flash evaporation, or spray drying. Alternatively, a fluorinated copolymer that is insoluble in the copolymerization reaction mixture and already precipitated may be isolated by filtration and further purified by washing with the solvent. The composition of the fluorinated copolymers can have a wide range with molar ratios of a first repeating unit to second repeating unit that are between 1:1 and 1:99. Preferably, the molar ratio of a first repeating unit to a second repeating unit is between 1:1 and 1:9, more preferably between 1:2 and 1:9 The fluorinated copolymers may comprise an additional repeating unis that is different from the first and second repeating units and may be incorporated to increase molecular weight or further modify copolymer properties. The additional repeating unit may be formed from comonomers that include tetrafluoroethylene, chlorotrifluoroethylene, vinylidene fluoride, vinyl fluoride, perfluoropropylvinyl ether, and ethylene. The additional repeating unit is preferably less than 50 mole percent, more preferably less than 25 mole percent with respect to the average repeating unit composition of the fluorinated copolymer.
Preferred fluorinated copolymer compositions having a backbone comprising a fluorinated and cyclic structure from a first repeating unit, and a second repeating unit with pendant amide functionality from a vinyl amide comonomer are shown in scheme (1), wherein n and m are fractional numbers that define the average repeating unit composition. Preferred vinyl amide comonomers include N-vinyl formamide (R1=H, R2=H) or N-vinyl-N-methyl acetamide (R1=CH3, R2=CH3). The fluorinated copolymer comprising a first repeating unit from PDD and a second repeating unit from N-vinyl formamide, poly(PDD-co-N-vinyl formamide), is formed in relatively high yields, is relatively easy to hydrolyze, and is most preferred.
A fraction between 1 and 100%, preferably greater than 50% of the pendant amide functionality from the second repeating unit of the fluorinated copolymer, may be transformed to pendant ammonium or pendant amine functionality by either acid or base hydrolysis methods, respectively, to form the amine derivatized fluorinated copolymer. Base hydrolysis using sodium hydroxide or potassium hydroxide (KOH) is preferred and avoids a subsequent ion exchange step to convert ammonium functionality to amine functionality. Base hydrolysis is carried out with the fluorinated copolymer dispersed or dissolved in a liquid medium such as lower alcohols (ROH) that include methanol, ethanol, or mixtures of these alcohols with water. Base hydrolysis in methanol using potassium hydroxide (KOH) is exemplified in scheme (II) wherein the first repeating unit is from PDD, and the second repeating unit is from N-vinyl amide. The fluorinated copolymer swells or dissolves in the alcohol as it slowly hydrolyzes and may be accelerated with heating of the reaction mixture. The amine derivatized fluorinated copolymer may then be separated from the reaction mixture by evaporation or precipitation in water. The amine derivatized fluorinated copolymer can be subsequently re-dissolved in the same alcohol or a different solvent for fabrication of a gas-separation layer in a thin-film composite membrane by solution casting.
A dilute solution of the amine derivatized fluorinated copolymer after hydrolysis is prepared for membrane fabrication at concentrations that are preferably less than 5%, more preferably less than 2%, and very preferably between 0.1% and 1%. Suitable solvents or solvent mixtures are those that will dissolve the amine derivatized fluorinated copolymer and evaporate at an appropriate rate to form the membrane in a timely manner. For example, suitable solvents include but are not limited to lower alcohols such as methanol and ethanol, mixtures of the preceding solvents with each other, water, or mixtures of the alcohols with fluorinated solvents that are organic-soluble, such as Novec® HFE7200 and HFE7300 (3M, St. Paul, MN) may also be used. Solvent mixtures with a fluorinated solvent may help to increase solubility for derivatized fluorinated copolymers having a relatively high mole fraction of the first repeating unit.
Solution casting is the preferred technique to form the membrane, preferably as a gas-separation layer in a thin-film composite membrane. Solution casting techniques include but are not limited to ring casting, dip-coating, spin-coating, slot-die coating, and Mayer rod coating. The solution is cast, and the solvent(s) are evaporated to form the “dry” gas-separation layer. The gas-separation layer thickness has a significant influence on the permeance of the thin-film composite membrane. The gas-separation layer is therefore thin and preferably has a thickness of 0.05-μm to 1.0-μm, more preferably 0.1-μm to 0.5-μm. A gas-separation layer in a thin-film composite membrane construction is exemplified in
The membrane may be fabricated by solution casting a gas-separation layer directly onto a substrate that includes a high-diffusion rate layer, which is also known as a gutter layer in the field of membrane technology. The gutter layer helps to facilitate formation of a gas-separation layer that is thin and predominantly laminar by preventing the casting solution from significantly penetrating other layers of the thin-film composite membrane such as a porous-layer support. A gutter layer is known in the field of membrane technology to increase overall permeance of a thin-film composite membrane, possibly by increasing permeation pathways from the gas-separation layer to the pores of the porous-layer support. The gutter layer is also very thin and preferably about 0.01-μm to about 1-μm, and more preferably 0.1-μm to 1-μm. Permeance, which is pressure normalized flux, is typically reported in gas permeance units or GPU, and has units of 106×cm3(STP)/cm2/sec/cmHg. The gutter layer preferably has a carbon dioxide permeance of at least 5000-GPU at 25° C., more preferably at least 10,000-GPU, and most preferably at least 10 times greater than the gas-separation layer.
Permeable materials for a gutter layer should be thermally and chemically stable, and highly permeable to CO2 but not necessarily selective over other gases such as nitrogen and methane. The permeable material is preferably a glassy polymer with a glass transition temperature higher than the working temperature of the thin-film composite membrane. Dilute solutions of the permeable material for a gutter layer are prepared at concentrations that are preferably less than 1%, and more preferably between 0.05% and 0.5%. The gutter layer may be fabricated by the same solution casting techniques mentioned previously onto a substrate that includes the porous-layer support. Residual or trace solvent remaining in the gutter layer should not interfere with subsequent processing steps. A preferred permeable material for the gutter layer includes Teflon® AF 2400 (The Chemours Co., Wilmington. DE), which is soluble in Novec® HFE7300 (3M, St. Paul, MN), Novec® FC770 (3M, St Paul, MN), and Opteon® SF10 (The Chemours Co., Wilmington, DE). Another preferred permeable material for the gutter layer is poly(5-trimethylsilyl propyne) (PTMSP). PTMSP is commercially available for Gelest (Morrisville, PA) and is soluble in toluene and heptane.
The porous-layer support reinforces and helps to strengthen the composite membrane such that the thin-film composite membrane may be fabricated into complex geometries that include spiral-wound or hollow-fiber membrane modules. The porous-layer support may be in the form of a flat sheet, hollow fiber, or tube. Suitable materials for a porous-layer support include but are not limited to polyvinylidine fluoride (PVDF), expanded polytetrafluoroethylene, polyacrylonitrile (PAN), polysulfone, and polyethersulfone. The porous-layer support may also comprise an even stronger backing material such as porous and non-woven polyester or polypropylene. Porous inorganic substrates such as silica or alumina may also be suitable materials for the porous-layer support. The porous-layer support should have a CO2 permeance that is greater than the gutter layer, preferably at least 2 times greater, and more preferably at least 5 times greater. Permeate gases should flow relatively unobstructed through the usually much thicker, porous-layer support having a preferred porosity that is at least 40%. The average pore size is preferably less 0.1-μm and more preferably between 0.01 and 0.03-μm, corresponding to molecular weight cut-offs of approximately 100,000 to 200,000 Daltons.
The thin-film composite membrane may be subjected to a thermal treatment step “annealed” to improve mechanical durability and long-term permeance and selectivity. The fluorinated copolymer in the gas-separation layer is annealed by heating the thin-film composite membrane to near or above the glass transition temperature of the fluorinated copolymer. The exact glass transition temperature will be dependent on the composition of the fluorinated copolymer. Generally, annealing temperatures for the preferred fluorinated copolymers are between 50 and 200° C., and preferably between 75 and 150° C. The thin-film composite membrane is preferably heated for 0.1 to 10 minutes, more preferably for 1 to 5 minutes. The appropriate annealing temperature and time should not degrade the other layers of the thin-film composite membrane.
The thin-film composite membrane having a gas-separation layer comprising the fluorinated copolymer that has been hydrolyzed is useful for the separation of CO2 from nitrogen or methane. In a separation process, the membrane is exposed to a flowing gaseous feed-mixture comprising CO2 and water vapor. A “driving force” is provided in which the carbon dioxide pressure on the feed-side is higher than on the permeate-side of the thin-film composite membrane. The driving force may be generated by applying a vacuum on the permeate-side and may be preferred, due to lower energy consumption, for separation of CO2 from low-pressure feed sources such as flue gas. Separation of carbon dioxide from the gaseous feed-mixture occurs through the membrane producing a permeate composition at the membrane permeate-side having a higher concentration of CO2 than the feed-mixture. Separation efficiency may be enhanced by having water vapor in the feed mixture and optionally in a sweep comprising water vapor at the permeate-side. The sweep also functions to increase the driving force by reducing the CO2 concentration.
Copolymerization of PDD and N-vinyl formamide at a 1:3 molar feed ratio: A 125-mL glass pressure tube equipped with a Teflon® screw cap and a magnetic stir bar was immersed into an ice bath. The pressure tube was flushed with argon and then loaded with 30 mL of methyl acetate, 30 mL of tert-butyl alcohol, 120 mg (0.73 mmol) AIBN (2,2′-Azobis(2-methylpropionitrile), 8.52 g (120 mmol) of previously vacuum distilled N-vinyl formamide and 9.76 g (40.0 mmol) of PDD (4,5-Difluoro-2,2-bis(trifluoromethyl)-1,3-dioxole). The pressure tube was sealed, and the reaction mixture was heated with magnetic stirring to 60-65° C. by immersing in an oil bath. The reaction mixture was stirred at temperature overnight. After cooling to ambient room temperature, the crude product as a precipitate in the reaction mixture was isolated on filter paper using a Buchner funnel. The precipitate was rinsed on the filter paper with 30 mL of fresh 1.1 mixture of methyl acetate and tert-butyl alcohol. The precipitate on the filter paper was dried in an oven at 60° C. for 5 hours to yield 14.0 g (77%) of white powder. The glass transition temperature from DSC was 172° C. From elemental analysis: C, 40.06%, H, 4.72%, N, 10.84%. The calculated PDD/N-vinyl formamide molar ratio from the % nitrogen in the copolymer was 1:4.2.
Copolymerization of PDD and N-vinyl formamide at a 1:1 molar feed ratio: A 125-mL glass pressure tube equipped with, a Teflon® screw cap and a magnetic stir bar was immersed into an ice bath. The pressure tube was flushed with argon and then loaded with 9 mL of methyl acetate, 9 mL of tert-butyl alcohol, 50 mg (0.30 mmol) AIBN (2,2′-Azobis(2-methylpropionitrile), 1.16 g (16 mmol) of previously vacuum distilled N-vinyl formamide and 4.0 g (16 mmol) of PDD (2,2-bistrifluoromethyl-4,5-difluoro-1,3-dioxole). The pressure tube was sealed, and the reaction mixture was heated with magnetic stirring to 60-65° C. by immersing in an oil bath. The reaction mixture was stirred at temperature overnight. After cooling to ambient room temperature, the reaction mixture was filtered on filter paper with a Buchner funnel. The precipitate was rinsed on the filter paper with 10 mL of fresh 1:1 mixture of methyl acetate and tert-butyl alcohol. The precipitate on the filter paper was dried in an oven at 60° C. for 5 hours to yield 2.3 g (45%) of an off-white powder. From elemental analysis: C, 36.1%, H, 3.22%, N, 7.25%. The calculated PDD/N-vinyl formamide molar ratio from the % nitrogen in the copolymer was 1:2.0.
Copolymerization of PDD and N-methyl-N-vinyl acetamide at a 1:3 molar feed ratio: A stainless-steel pressure vessel of a 125-mL stainless-steel pressure reactor, equipped with magnetic-mechanical stirring, was loaded with 123 mg (0.75 mmol) AIBN (2,2′-Azobis(2-methylpropionitrile). The pressure vessel was connected to the reactor head, evacuated, and chilled in an ice water bath. A mixture of 30 mL of methyl acetate and 30 mL of tert-butyl alcohol was added by transfer line into the pressure reactor followed by 11.2 g (113 mmol) of previously vacuum distilled N-methyl-N-vinyl acetamide. The pressure reactor was briefly re-evacuated with stirring to remove oxygen and then backfilled to atmospheric pressure with argon. 5.4-mL (˜9.2-g (38 mmol) of PDD (2,2-bistrifluoromethyl-4,5-difluoro-1,3-dioxole) was added by syringe through the transfer line and the pressure reactor was closed and heated to 60-65° C. The maximum pressure was 35 psia and the reaction mixture was stirred at temperature overnight at which point the pressure had dropped to 15 psia. After cooling to ambient room temperature and equilibrating any residual pressure/vacuum, the pressure reactor was opened and the crude product as a viscous slightly yellow solution was poured into a 250-mL tared wide-mouth jar. The viscous solution was carefully evaporated in a vacuum oven (60° C.) to constant weight to yield an off-white glassy solid polymer (yield=16.0-g, 78%). From elemental analysis: C, 43.7%, H, 5.93%, N, 5.95%, F, 14.4%. The calculated PDD/N-Methyl-N-vinyl acetamide molar ratio from the % nitrogen in the copolymer was 1:2.8.
Copolymerization of PDD and 1-vinyl-2-pyrrolidinone at a 1:3 molar feed ratio: A 125-mL stainless-steel pressure reactor equipped with magnetic-mechanical stirring is chilled in an ice bath. The pressure reactor is evacuated, backfilled with argon, then loaded with 120-mg (0.73 mmol) AIBN (2,2′-Azobis(2-methylpropionitrile) that is pre-dissolved in a mixture of 30 mL of methyl acetate and 30 mL of tert-butyl alcohol. 12.4 g (112 mmol) of previously vacuum distilled 1-vinyl-2-pyrrolidinone is added and the pressure reactor is briefly re-evacuated to remove oxygen and then backfilled with argon to atmospheric pressure 9.0-g (37 mmol) of PDD is added and the pressure reactor is closed and heated to 60-65° C. The reaction mixture is stirred at temperature overnight. After cooling to ambient room temperature and equilibrating any residual pressure/vacuum, the pressure reactor is opened and the crude product as a viscous slightly yellow solution is poured into a 250-mL tared wide-mouth jar. The viscous solution is carefully evaporated in a vacuum oven (60° C.) to constant weight to yield an off-white glassy solid polymer. The expected yield is greater than 50%. The expected PDD/1-vinyl-2-pyrrolidinone molar ratio from elemental analysis and the % nitrogen in the copolymer is approximately 1:4.
Copolymerization of perfluoro(4-vinyloxyl-1-butene) (PVOB) and N-vinyl formamide at a 1:3 molar feed ratio: PVOB may be prepared as outlined in U.S. Pat. No. 4,897,457 A 125-mL stainless-steel pressure reactor equipped with magnetic-mechanical stirring is chilled in an ice bath. The pressure reactor is evacuated, backfilled with argon, then loaded with 120-mg (0.73 mmol) AIBN (2,2′-Azobis(2-methylpropionitrile) that is pre-dissolved in a mixture of 30 mL of methyl acetate and 30 mL of tert-butyl alcohol. 8.5 g (112 mmol) of previously vacuum distilled N-vinyl formamide is added and the pressure reactor is briefly re-evacuated to remove oxygen and then backfilled with argon to atmospheric pressure. 10.4-g (37 mmol) of PVOB is added and the pressure reactor is closed and heated to 60-65° C. The reaction mixture is stirred at temperature overnight. After cooling to ambient room temperature and venting any residual pressure, the crude product as a precipitate in the reaction mixture is poured from the pressure reactor and isolated on filter paper using a Buchner funnel. The precipitate is rinsed on the filter paper with 30 mL of fresh 1:1 mixture of methyl acetate and tert-butyl alcohol. The precipitate on the filter paper is dried in a vacuum oven at 60° C. to constant weight, yielding a white glassy polymer. The expected PVOB/N-vinyl formamide molar ratio from elemental analysis and the % nitrogen in the copolymer is approximately 1:5.
Fluorinated copolymer hydrolysis: 4.0 g of copolymer from example 1, 2.0 g potassium hydroxide, 50 mL methanol, and 5 mL of deionized water were added to a round bottom flask equipped with magnetic stirring and a reflux condenser. The hydrolysis mixture was heated to reflux with stirring for 2 hours and then cooled to ambient room temperature. 50 mL of water was added to the flask, the reaction mixture was heated without the condenser to 80° C. to evaporate most of the methanol and precipitate the now hydrolyzed and amine derivatized fluorinated copolymer. The precipitate was filtered on filter paper with a Buchner funnel, washed with 50 mL of deionized water and isolated as a tan solid (3.4 g) after drying at 60° C. for 5 hours. The fraction of amide groups that were hydrolyzed is estimated at between 60 and 80% from titration of a dilute solution of the amine derivatized fluorinated copolymer with hydrochloric acid.
Thin-film composite membrane from fabrication of a gas-separation layer on a Teflon® AF 2400/polyacrylonitrile substrate: A substrate consisting of a gutter layer and a porous-layer support was first prepared by casting a 0.1% (w/w) solution of Teflon® AF 2400 in Novec® FC770 on a polyacrylonitrile (PAN) ultra-filtration membrane (SEPRO PAN 350), having an approximately 150,000 Dalton molecular weight cut-off. After drying, the CO2 permeance of the Teflon® AF 2400 gutter layer/PAN composite was greater than 10,000-GPU. A 0.2% (w/w) solution of the hydrolyzed and derivatized fluorinated copolymer of example 6 was prepared in methanol and syringe filtered through 1-μm glass microfiber. The surface of a 3″ diameter circle of the gutter layer/PAN composite in a ring holder was covered with the solution. The holder was slightly tilted, and the excess solution was pipetted away. The remaining wet film was then dried in a horizontal positon at ambient room temperature under a dry nitrogen atmosphere to form the gas-separation layer. A protective layer from a 0.1% (w/w) solution of Teflon® AF 2400 in Novec® FC770 was subsequently ring cast on top of the separation layer in a similar manner.
Thin-film composite membrane from fabrication of a gas-separation layer on a poly(trimethylsilyl propyne)/polyvinylidine fluoride substrate: A substrate consisting of a gutter layer and a porous-layer support was first prepared by casting a 1% (w/w) solution of poly(trimethylsilyl propyne) (PTMSP) in heptane on a polyvinylidine fluoride (PVDF) ultra-filtration membrane (Synder Filtration, Vacaville CA), having a 100,000 Dalton molecular weight cut-off. The CO2 permeance of the PTMSP gutter layer/PVDF composite was greater than 10,000-GPU. A 3″ diameter circle of the gutter layer/PVDF composite was placed in a ring holder and the surface was covered with the 0.2% (w/w) solution of the hydrolyzed and derivatized fluorinated copolymer that was prepared in example 7 The holder was slightly tilted, and the excess solution was pipetted away. The remaining wet film was then dried in a horizontal positon at ambient room temperature under a dry nitrogen atmosphere to form the gas-separation layer. A protective layer from a 0.1% (w/w) solution of Teflon® AF 2400 in Novec® FC770 was subsequently ring cast on top of the separation layer in a similar manner.
Mixed-gas permeance and selectivity testing of CO2 over nitrogen or methane: Membranes (47-mm diameter circles, 16.85 cm2 active area) were tested for CO2 permeance and selectivity in a stainless-steel crossflow cell at ambient room temperature. CO2, nitrogen, or methane was fed from separate gas cylinders through mass flow controllers and then mixed. The gas mixture contained 10 to 40% CO2 at feed pressures of 30 to 90 psig. The gas flow was humidified before entering the crossflow cell by passing it through a stainless-steel water bubbler. The feed pressure was regulated by a backpressure regulator attached to the retentate port. The permeate flow rate at atmospheric pressure was measured using an Agilent 1100 flowmeter. The CO2 concentration in the permeate was measured using a Landtec 5000 biogas analyzer. The relative humidity in the feed was estimated from measurements of the relative humidity in the retentate and the permeate at atmospheric pressure. Table 1 shows high CO2 permeance and high selectivity over nitrogen or methane at a 30-psig feed pressure (40% CO2) for the membrane of example 7. Table 2 shows high CO2 permeance and high selectivity over nitrogen at various feed pressures for the membrane of example 8.
aafter 4 months
a85% estimated relative humidity
This application claims the benefit of priority to U.S. Provisional Patent Application No. 63/188,592, filed on May 14, 2021.
This invention was made with government support under 2017-33610-27019 awarded by the United States Department of Agriculture. The government may have certain rights in the invention.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2022/028905 | 5/12/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63188592 | May 2021 | US |
